Method for manufacturing polyester fiber structures and method for manufacturing medical uniforms

Abstract

A method for producing a polyester fiber structure that is excellent in antibacterial properties and washing durability is provided. [Solution] A method for producing a polyester fiber structure, comprising: a pre-heat treatment step of heat-treating a fiber substrate containing polyester fibers with a single fiber fineness of 0.3 dtex to 5.0 dtex at an ambient temperature of 110°C to 210°C so that the rate of change in weave density in the warp direction of the fiber substrate containing the polyester fibers before and after the heat treatment is -3.0% to 3.0%; a treatment solution preparation step of preparing a treatment solution containing 0.004 mass% or more of a quinoline-based compound; a chemical solution treatment step of immersing the fiber substrate containing the polyester fibers in the treatment solution and treating it by bath processing or pad processing; and a post-heat treatment step of dry-heat treating the chemically-treated fiber substrate containing the polyester fibers.

Description

[Technical Field]

[0001] This invention relates to a method for producing a polyester fiber structure with excellent antibacterial properties and wash durability, and to a method for producing medical uniforms. [Background technology]

[0002] Hospital-use textile products, such as white coats worn by medical personnel in hospitals and clinics, are often subjected to repeated industrial washing in hot water at temperatures of 60°C to 80°C for hygiene reasons. Therefore, antibacterial properties that can withstand high-temperature washing are necessary.

[0003] While the mainstream antibacterial processing technology for synthetic fiber products involves applying antibacterial agents after the product has been made into fabric or other materials, from a productivity standpoint, this method generally has the drawback of low antibacterial properties after washing, as the antibacterial agent washes off during washing.

[0004] In response to this problem, studies have been conducted to improve antibacterial properties after washing. For example, Patent Document 1 proposes applying 2-pyridylthiol-1-oxide zinc (hereinafter referred to as pyrithione zinc), a type of pyridine-based antibacterial agent, to a fiber structure by heat treatment at a specific temperature under normal or pressurized pressure. It is described that this results in a fiber structure with excellent antibacterial properties that can withstand industrial washing at a temperature of 85°C.

[0005] Furthermore, Patent Document 2 proposes heat-treating oxolinic acid under pressure in a treatment bath at a specific temperature. It is stated that this can impart antibacterial properties. [Prior art documents] [Patent Documents]

[0006] [Patent Document 1] Japanese Patent Publication No. 2000-8275 [Patent Document 2] Japanese Patent Publication No. 2021-42498 [Overview of the project] [Problems that the invention aims to solve]

[0007] The method described in Patent Document 1 has high antibacterial properties and wash durability, but because it uses an antibacterial agent containing zinc ions, there is a problem in that the treatment of wastewater generated after the application of the antibacterial agent is difficult. There is also the problem that it may affect dyeability.

[0008] The method described in Patent Document 2 uses oxolinic acid, an organic carboxylic acid compound, and therefore does not have the wastewater treatment problem described in Patent Document 1. However, our own investigation has revealed that depending on the processing steps and the composition of the substrate used, the antibacterial properties may be low.

[0009] The present invention was made to solve the above problems, and aims to provide a method for producing a polyester fiber structure that is excellent in antibacterial properties and wash durability, when imparting antibacterial properties to a polyester fiber structure without using antibacterial agents containing zinc ions or the like. [Means for solving the problem]

[0010] As a result of diligent research by the inventors, it has been found that a polyester fiber structure with excellent antibacterial properties and wash durability can be obtained by attaching a specific amount of quinoline compound to a fiber base material containing polyester fibers, using polyester fibers with a specific single fiber fineness, and then heat-treating the fiber base material containing polyester fibers at a specific temperature so that the weave density in the warp direction stays within a specific rate of change, followed by antibacterial processing. In particular, the improvement in antibacterial properties and wash durability by controlling the rate of change in the weave density in the warp direction within a specific range during the preheat treatment process before antibacterial processing is a newly discovered effect by the inventors.

[0011] In other words, the present invention has the following configuration in order to solve the above problems. (1) A pre - heat treatment step of heat - treating a fiber base material containing polyester fibers with a single - fiber fineness of 0.3 dtex or more and 5.0 dtex or less at an atmospheric temperature of 110°C or more and 210°C or less so that the change rate of the warp - wise weaving density of the fiber base material containing the polyester fibers before and after the heat treatment is - 3.0% or more and 3.0% or less, A treatment - liquid preparation step of preparing a treatment liquid containing a quinoline - based compound at 0.004% by mass or more based on the mass of the treatment liquid, A chemical - liquid treatment step of immersing the fiber base material containing the polyester fibers in the treatment liquid and treating it by in - bath processing or padding processing, A post - heat treatment step of dry - heat - treating the fiber base material containing the polyester fibers after the chemical - liquid treatment, A method for manufacturing a polyester - fiber structure having the above steps. (2) Among the fibers constituting the fiber base material containing the polyester fibers, the polyester fibers with a single - fiber fineness of 0.3 dtex or more and 5.0 dtex or less are contained at 40% by mass or more based on the mass of the entire fiber base material. The method for manufacturing a polyester - fiber structure according to (1). (3) The quinoline - based compound is at least one compound selected from oxolinic acid, ciprofloxacin, levofloxacin, moxifloxacin, garenoxacin, and sitafloxacin. The method for manufacturing a polyester - fiber structure according to (1) or (2). (4) The quinoline - based compound is oxolinic acid. The method for manufacturing a polyester - fiber structure according to (1) or (2). (5) In the chemical - liquid treatment step of treating by in - bath processing, the bath ratio of the treatment liquid (mass of the fiber base material containing the polyester fibers: mass of the treatment liquid) is 1:5 to 1:30. The method for manufacturing a polyester - fiber structure according to (1) or (2). (6) A method for manufacturing a medical uniform having a step of sewing a medical uniform using a polyester - fiber structure produced by the method for manufacturing a polyester - fiber structure according to (1) or (2).

Advantages of the Invention

[0012] According to the present invention, it is possible to provide a method for producing a polyester fiber structure excellent in antibacterial properties and washing durability thereof.

Mode for Carrying Out the Invention

[0013] 〔Method for Producing Polyester Fiber Structure〕 Hereinafter, the present invention will be described in detail together with preferred embodiments, but it is not limited to these embodiments. The method for producing a polyester fiber structure of the present invention includes a pre-heat treatment step of heat-treating a fiber base material containing polyester fibers having a single fiber fineness of 0.3 dtex or more and 5.0 dtex or less so that the change rate of the weaving density in the longitudinal direction of the base material containing the polyester fibers before and after the heat treatment is -3.0% or more and 3.0% or less at an atmospheric temperature of 110°C or more and 210°C or less, a treatment liquid preparation step of preparing a treatment liquid containing a quinoline-based compound of 0.004% by mass or more based on the mass of the treatment liquid, a chemical liquid treatment step of immersing a fiber base material containing the polyester fibers in the treatment liquid and treating it by in-bath processing or padding processing, and a post-heat treatment step of dry-heat treating the fiber base material containing the polyester fibers treated with the chemical liquid, and is characterized by having these steps.

[0014] <Pre-heat Treatment Step> (Fiber Base Material) As the fiber base material constituting the polyester fiber structure, cloth-like materials such as woven fabrics, knitted fabrics, and non-woven fabrics can be preferably used. Also, the form of the fiber base material may be either a filament yarn or a spun yarn, and is not limited thereto. And, if necessary, synthetic fibers such as acrylic and nylon other than polyester fibers, natural fibers such as cotton, wool, and silk, and semi-synthetic fibers such as rayon and acetate can be combined and used in forms such as interweaving, interknitting, mixed weaving, mixed spinning, and mixed fiber spinning.

[0015] The aforementioned fiber base material contains polyester fibers with a single fiber fineness of 0.3 dtex or more and 5.0 dtex or less. Furthermore, of the fibers constituting the fiber base material, it is preferable that polyester fibers with a single fiber fineness of 0.3 dtex or more and 5.0 dtex or less account for 40% or more by mass of the total mass of the fiber base material, more preferably 60% or more by mass, and even more preferably 75% or more by mass. By setting the proportion to the above range, the proportion of polyester fibers to which the quinoline compound is attached increases, and as a result, the antibacterial properties of the resulting polyester fiber structure are further enhanced. From the viewpoint of improving antibacterial properties, the higher the proportion of polyester fibers, the better. Note that "the proportion of polyester fibers to the total mass of the fiber base material" may be written as "the proportion of polyester fibers".

[0016] The polyester fibers described above are fibers produced by melt-spinning a resin made of polyester. The polyester used here is a general polyester produced by polymerizing terephthalic acid or its ester derivative as a carboxylic acid component with alkylene glycol components such as ethylene glycol and trimethylene glycol, and known polyester fibers can be used.

[0017] The single fiber fineness of the polyester fiber is 0.3 dtex or greater, preferably 1.0 dtex or greater. It is also 5.0 dtex or less, preferably 4.0 dtex or less, and more preferably 2.0 dtex or less. If the single fiber fineness is less than 0.3 dtex, antibacterial properties cannot be obtained. The detailed mechanism is unknown, but it is presumed that when the single fiber fineness is small, the polymer becomes oriented, making it difficult for the antibacterial agent to penetrate into the inside of the fiber, and the antibacterial agent attached to the surface falls off in subsequent processes, resulting in no antibacterial properties being obtained. On the other hand, if the single fiber fineness is greater than 5.0 dtex, the fiber surface area per unit weight becomes small, the contact area between the antibacterial agent and the fiber becomes small, and sufficient antibacterial properties cannot be obtained as a polyester fiber structure.

[0018] (Percentage change in weave density in the warp direction of the fibrous base material) Before and after the preheat treatment described later, the change rate of weave density in the warp direction of the fibrous substrate containing the polyester fibers (hereinafter sometimes referred to as "polyester fiber substrate") is -3.0% or more, preferably -1.5% or more, and 3.0% or less, preferably 1.5% or less. One method for achieving the change rate of weave density in the warp direction is to adjust the tension in the warp and weft directions during the preheat treatment, and this can be adjusted considering the shrinkage characteristics of the polyester fiber substrate. Among these methods, the change rate of weave density in the warp direction can be easily adjusted by adjusting the tension in the weft direction. For example, in the preheat treatment, tension is applied to the weft direction (width direction) of the polyester fiber substrate using a pin tenter machine or the like to adjust the width of the polyester fiber substrate to a predetermined set width before processing. In this case, if the setting width of the pin tenter machine is widened relative to the length (width) of the polyester fiber substrate in the weft direction before the preheat treatment and heat treatment is performed, the polyester fiber substrate is pulled in the weft direction, the density of fibers in the warp direction becomes sparser, and the value of the weave density in the warp direction becomes smaller. By utilizing this, the rate of change in weave density in the warp direction can be adjusted to a desired range by comprehensively considering the shrinkage characteristics of the polyester fiber base material. From this viewpoint, it is preferable to set the pin tenter machine's setting width to -3.0% or more and 3.0% or less with respect to the transverse length (width) of the polyester fiber base material before preheat treatment.

[0019] By adjusting the tension so that the change in weave density in the vertical direction is between -3.0% and 3.0% before and after preheat treatment, antibacterial properties and wash durability can be obtained. Although the detailed reason is unknown, it is presumed that by setting the change in weave density in the vertical direction to the above range, the crystallinity of the polyester fibers is within an appropriate range, and a sufficient amount of antibacterial agent remains after washing, resulting in wash durability. In other words, if the change in weave density in the vertical direction is less than -3.0%, the tension in the horizontal direction applied to the polyester fiber base material is too high, causing the amorphous region in the fiber to become small and the crystalline region to become large, making it difficult for the antibacterial agent to be fixed inside the fiber. Therefore, it is thought that a sufficient amount of antibacterial agent does not remain after washing, and wash durability decreases. On the other hand, if the change in weave density in the vertical direction is greater than 3.0%, the tension in the horizontal direction applied to the polyester fiber base material is insufficient, resulting in low crystallinity of the polyester fibers. Although a large amount of antibacterial agent is fixed inside the fiber, the crystalline structure is too loose and cannot strongly hold the antibacterial agent, so it is thought that the amount of antibacterial agent lost during washing increases, and wash durability decreases. The rate of change in weave density in the vertical direction is measured by the method described in the examples.

[0020] (Atmospheric temperature) The ambient temperature range during preheat treatment is 110°C or higher, preferably 170°C or higher, and more preferably 180°C or higher. It is also 210°C or lower, preferably 200°C or lower, and more preferably 190°C or lower. Dry heat treatment at an ambient temperature of 190°C is preferable because it minimizes the amount of antibacterial agent lost during washing. If preheat treatment is performed at an ambient temperature below 110°C, or if preheat treatment is not performed, the amount of antibacterial agent lost during washing increases, reducing the antibacterial properties after washing, i.e., the wash durability. Similarly, if preheat treatment is performed at an ambient temperature above 210°C, the amount of antibacterial agent lost during washing increases, reducing the antibacterial properties after washing, i.e., the wash durability. In addition, the hardening of the polyester affects the texture, which is undesirable when considering use in textile products.

[0021] <Processing solution preparation step> The present invention provides a method for producing a polyester fiber structure, comprising a treatment solution preparation step of preparing a treatment solution containing a predetermined amount of a quinoline compound. The resulting polyester fiber structure can be processed in combination with functional processing agents, as described later, without affecting its antibacterial properties. Therefore, the treatment solution may contain other agents, such as dyes, water absorbents, and fluorescent whitening agents, in any amount appropriate to the desired function.

[0022] (Quinoline compounds) The above quinoline compounds include oxolinic acid (5-ethyl- 5,8-dihydro- 8-Oxo-[1,3]dioxolo[4,5-g]quinoline-7-carboxylic acid), ciprofloxacin (1-cyclopropyl -6 -Fluoro-4-oxo-7- (piperazine-1-yl)-1,4-dihydroquinoline-3- Carboxylic acid), levofloxacin ((3S)-9-fluoro-3-methyl-10-(4-methyl-1-piperazinyl)-7-oxo-2,3-dihydro-7H-pyrido[1,2,3-de][1,4]benzoxazine-6-carboxylic acid), moxifloxacin ((1S,6S)-1-cyclopropyl-7-(2,8-diazabicyclo[4.3.0]non-8-yl)-6-fluoro-8-methoxy-4-oxo-1,4-dihydroquinoline-3-carboxylic acid), galenoxacin (1-cyclopropyl-8 It is preferable that the compound is at least one compound selected from the group consisting of -(difluoromethoxy)-7-[(1R)-1-methyl-2,3-dihydro-1H-isoindole-5-yl]-4-oxo-1,4-dihydroquinoline-3-carboxylic acid and sitafloxacin (7-[(7S)-7-amino-5-azaspiro[2,4]heptan-5-yl]-8-chloro-6-fluoro-1-[(1R,2S)-2-fluorocyclopropyl]-4-oxo-1,4-dihydroquinoline-3-carboxylic acid). Among these, it is more preferable that the quinoline compound be an oxolinic acid.

[0023] The quinoline compounds listed above may also be alkali metal salts such as sodium or potassium salts, alkaline earth metal salts such as calcium or magnesium salts, or metal salts such as aluminum or iron salts.

[0024] The content of the quinoline compound in the treatment solution is 0.004% by mass or more, preferably 0.008% by mass or more, relative to the mass of the treatment solution. An antibacterial effect is obtained by having a content of 0.004% by mass or more. On the other hand, if the mass of the quinoline compound is too high, a large amount of white quinoline compound will adhere to the surface of the polyester fiber structure, causing the polyester fiber structure to whiten (i.e., lightness L * (The concentration increases), and there is also a tendency for the hue of the polyester fiber structure to change. For this reason, the amount of quinoline compound is preferably 0.030% by mass or less, and more preferably 0.015% by mass or less, relative to the mass of the treatment solution. By using the quinoline compound within the above range, good antibacterial properties can be obtained.

[0025] <Chemical treatment process> The present invention provides a method for producing a polyester fiber structure, comprising a chemical treatment step in which a fiber base material containing the polyester fibers is immersed in the treatment solution and treated by bath processing or pad processing.

[0026] The aforementioned chemical treatment is achieved by either bath processing or pad processing. Bath processing refers to a method in which a fibrous substrate containing polyester fibers is immersed in a bath containing the treatment solution and heated to adhere the treatment solution to the fibrous substrate containing polyester fibers. Pad processing refers to a method in which a fibrous substrate containing polyester fibers is immersed in the treatment solution, compressed with a mangle roller or the like to ensure a certain amount of the treatment solution adheres to it, and then subjected to dry heat treatment in a dryer or moist heat treatment under saturated steam at 100°C to adhere the treatment solution to the fibrous substrate containing polyester fibers.

[0027] In the bath processing, the preheat-treated polyester fiber substrate is placed in a treatment solution containing a quinoline compound at a bath ratio (mass of polyester fiber substrate:mass of treatment solution) of 1:5 to 1:30. Subsequently, the substrate is heat-treated in a sealed container under atmospheric pressure or under pressure at a bath temperature of 90°C to 140°C, preferably 110°C to 140°C. By performing chemical treatment at a bath ratio within this range, the fiber substrate and the quinoline compound come into efficient contact, providing a polyester fiber structure that retains antibacterial properties even after washing.

[0028] In pad processing, the fiber substrate containing the preheat-treated polyester fibers is immersed in a treatment solution containing a quinoline compound, pressed with a mangle roller to ensure the treatment solution adheres, then the fiber substrate containing polyester fibers is set in a pin tenter and subjected to moist heat treatment at 130°C for 2 minutes. When using a fiber substrate containing dyed polyester fibers, the preheat-treated fiber substrate containing polyester fibers is placed in a treatment solution containing a dye at a bath ratio (mass of fiber substrate containing polyester fibers:mass of treatment solution) of 1:5 to 1:30, and then subjected to heat treatment in a sealed container under atmospheric pressure or under pressure at a temperature of 90°C to 140°C. After that, pad processing is performed.

[0029] <Post-treatment process> The present invention relates to a method for manufacturing a polyester fiber structure, which includes a post-heat treatment step in which a fiber substrate containing the chemically treated polyester fibers is subjected to dry heat treatment. In the post-heat treatment step, the fiber substrate containing the chemically treated polyester fibers is set in a pin tenter and subjected to dry heat treatment for 15 seconds to 5 minutes at an ambient temperature of 130°C to 190°C, preferably 150°C to 190°C. This dry heat treatment improves the antibacterial properties after washing, i.e., the washing durability.

[0030] <Post-processing process> After the aforementioned post-heat treatment process, a polyester fiber structure is obtained. However, as with general polyester fiber structures, various finishing processes can be carried out further. For example, calendering, which improves the light reflectivity of the surface of the polyester fiber structure and gives it a glossy appearance by compressing and smoothing it using rollers, and napping, which creates a fluffy surface to provide heat retention and flexibility by scratching or abrading the surface of the polyester fiber structure using needles or abrasive cloths. Of course, the polyester fiber structure obtained by these finishing processes is also included in the polyester fiber structure obtained by the method for manufacturing polyester fiber structures of the present invention.

[0031] <Antibacterial properties of polyester fiber structures> The polyester fiber structure provided by the method for manufacturing the polyester fiber structure of the present invention exhibits an antibacterial activity value of A after 50 high-temperature accelerated washes, according to the antibacterial evaluation method described in the SEK Mark Textile Product Certification Standards established by the Japan Textile Evaluation Technology Council. 50 The value becomes greater than the standard fabric growth value F. In other words, it is possible to provide a polyester fiber structure that has antibacterial properties that meet the evaluation criteria for "antibacterial processing (specific use: red)" of the SEK mark textile product certification standards after 50 high-temperature accelerated washes. The high-temperature accelerated wash and antibacterial properties tests will be evaluated using the methods described later.

[0032] [Application] The polyester fiber structure provided by the method for manufacturing the polyester fiber structure of the present invention can be applied to various uses where high antibacterial properties are required, and can be used, for example, as fabric for clothing, bedding, towels, rugs, curtains, sheets, and the like.

[0033] As clothing, it can be used in general clothing, uniforms, formal and business attire, work clothes, sportswear, and medical uniforms such as white coats, scrubs, scrubs, doctor's coats, nurse uniforms, and tunics worn by medical professionals. The polyester fiber structure provided by the method for producing the polyester fiber structure of the present invention is particularly preferable to be included in medical uniforms. [Examples]

[0034] Next, the method for manufacturing the polyester fiber structure of the present invention will be explained in more detail with reference to examples, but the method for manufacturing the polyester fiber structure of the present invention is not limited to these examples. The washing method and various test methods in the examples were carried out according to the following methods.

[0035] (Washing method) The process followed the "Washing Method for SEK Mark Textile Products," which is the certification standard of the Japan Textile Evaluation Technology Council. Specifically, a washer washing machine was used, and 120 mL of "JAFET Standard Blended Detergent" was added to 90 L of water to create the washing solution. Subsequently, the polyester fiber structure and, if necessary, the load fabric were added to this washing solution so that the bath ratio (mass of polyester fiber structure:mass of washing solution) was 1:30, and the total mass of the polyester fiber structure and load fabric was adjusted to 3 kg. After that, 1) Wash at 80°C for 120 minutes. 2) Drainage The following was done, and rinsing was performed using a household washing machine with a centrifugal wringing device, standard washing capacity, and standard water volume, conforming to the JIS C 9606:2007 (electric washing machine) standard, as specified in "Appendix 1 Test Methods by Symbol - Washing Method (Water Washing), No. 103" of JIS L 0217:1995 "Symbols and Methods of Displaying for Handling Textile Products". That is, 3) Thoroughly dehydrate the polyester fiber structure and load fabric for 3-5 minutes. 4) 15-minute overflow rinse (aim for 3-5 replacement water volumes) 5) Dehydrate using the same method as in 4). This was done. Then, steps 3) to 5) were repeated a total of four times, and then steps 1) to 5) were repeated a total of five times using a washer washing machine and a household washing machine. Finally, only the polyester fiber structure was removed. 6) Use a household washing machine and perform a 5-minute overflow rinse (aim for 3-5 water replacement cycles). 7) Dehydrate using the same method as in 3). 8) Drying at a temperature of 80°C or lower. The following was done. Regarding step 8), the products were dried by hanging or laying them flat in a place where they were not exposed to direct sunlight.

[0036] (Antibacterial test) 1) Test method: The test was conducted using the bacterial solution absorption method based on JIS L 1902:2015 "Test method and antibacterial effect of textile products". The test was also conducted under the condition that 0.050% by mass of the nonionic surfactant "Tween" (registered trademark) 80 was added to the test bacterial suspension relative to the mass of the polyester fiber structure. 2) Test strain: Staphylococcus aureus 3) Evaluation Method: The evaluation criteria for antibacterial processing (specific use: red) in "18.3 Evaluation Criteria for Bacterial Solution Absorption Method" of the "SEK Mark Textile Product Certification Standards" mentioned above were followed. Specifically, the antibacterial activity value of the polyester fiber structure after antibacterial processing, after 50 washes, was set to A. 50 If the growth value of an unwashed standard cloth is F, then A 50 >When F is true, that is, A 50 -If F > 0.0, then antibacterial properties are good, A 50 If -F ≤ 0.0, it was determined to be poor antibacterial. The standard fabric refers to the JIS L 0803 attached white cloth (cotton No. 3-1) that has been treated with water washing, as described in the proviso of "3.1 Target specimen (control specimen)" in JIS L 1902:2015 "Test method and antibacterial effect of textile products," which is sold by the Japan Textile Evaluation Technology Council as a standard fabric (cotton) for antibacterial testing.

[0037] Here, the antibacterial activity value A after n washes. nand the growth value F of the standard cloth was taken as the value calculated by the following formulas (2) and (3). A n =(log C t -log C o )-(log T t -log T o ) …(2) F=log C t -log C o …(3) log C o : Common logarithm of the arithmetic mean of the viable cell counts of three specimens immediately after inoculation of the test bacteria on the standard cloth log C t : Common logarithm of the arithmetic mean of the viable cell counts of three specimens after 18-hour culture of the standard cloth log T o : Common logarithm of the arithmetic mean of the viable cell counts of three specimens immediately after inoculation of the test bacteria in the obtained fiber structure log T t : Common logarithm of the arithmetic mean of the viable cell counts of three specimens after 18-hour culture in the obtained fiber structure In addition, the antibacterial activity value A0 before washing the polyester fiber structure was also evaluated by the above method.

[0038] (Color measurement) Using a spectrophotometer CM-3700d (manufactured by Konica Minolta Co., Ltd.), the diffuse reflectance of the polyester fiber structure was measured under a D65 light source and a 10-degree field of view, and the lightness L * was measured. Here, the lightness L * refers to the L * a * b * value defined by the "3.3 CIE1976 lightness index" of the CIE 1976 L * a*b* color space) in JIS Z8781-4:2013 (Color measurement - Part 4: CIE 1976 L

[0039] (Pick-up rate) The pick-up rate is the ratio of the mass difference between the fiber substrate containing polyester fiber after immersion in the processing liquid and squeezing with a mangle roller or the like to the mass of the fiber substrate containing polyester fiber before immersion in the processing liquid, and is represented by the following formula (3). Pickup rate (%) = ((Mass of polyester fiber substrate after immersion and wringing - Mass of polyester fiber substrate before immersion) / Mass of polyester fiber substrate before immersion) × 100 …(3).

[0040] (Percentage change in weave density in the warp direction of the fibrous base material) The warp-direction weave density of polyester fiber substrates before and after preheat treatment was measured using a densimeter (manufactured by Tamamura Co., Ltd.), an automatic woven fabric density measuring instrument. Subsequently, the rate of change in weave density before and after preheat treatment was calculated. The rate of change in warp-direction weave density of the fiber substrate was calculated using the following formula (4). The percentage change in weave density in the warp direction of the fibrous base material is (%) = ((Warp weave density after heat treatment - Warp weave density before heat treatment) / Warp weave density before heat treatment) × 100 …(4).

[0041] [Example 1] (1) Pre-heat treatment process A 148cm wide fabric was heat-treated at an ambient temperature of 190°C for 1 minute, using polyester fibers (single fiber fineness: 3.5 dtex) of 167dtex-48 filament (hereinafter sometimes referred to as 167T-48F; the same applies hereafter) for both the warp and weft. The fabric was then subjected to heat treatment with tension sufficient to eliminate wrinkles at a set width of 148cm. This process produced a fibrous base material containing polyester fibers.

[0042] (2) Process liquid preparation step A treatment solution consisting of a quinoline compound and a staining acid was prepared. The following chemicals were used, and the mass ratio of each chemical to the mass of the treatment solution was adjusted as follows. • Quinoline compound: Oxolinic acid, 0.004% by mass • Staining acid: Mixed aqueous solution of 70% by mass acetic acid / 30% by mass sodium acetate, 0.005% by mass In addition, in the "Manufacturing Method" column of Table 1, "the ratio of the mass of the quinoline compound to the mass of the processing solution" is written as "quinoline compound".

[0043] (3) Chemical treatment process A fibrous substrate containing polyester fibers was immersed in the treatment solution prepared above and subjected to chemical treatment under pressure at 130°C for 30 minutes in a bath processing machine. Afterward, the fibrous substrate containing polyester fibers was removed from the bath processing machine and washed and dewatered. The bath processing machine used was the following apparatus, and the bath ratio was as follows. • Bath processing machine: 12-color rotary pot dyeing test machine (MINI-COLOUR 12EL model: manufactured by Texam Giken Co., Ltd.) Bath ratio (mass of fibrous substrate containing polyester fibers:mass of treatment solution): 1:10.

[0044] (4) Post-heat treatment process A fibrous substrate containing chemically treated polyester fibers was set in a pin tenter, and a dry heat setting was performed at 130°C for 1 minute to obtain a polyester fiber structure.

[0045] [Example 2] In Example 1, the procedure was carried out in the same manner as in Example 1, except that the ambient temperature for the post-heat treatment step was 170°C for 1 minute.

[0046] [Example 3] In Example 2, the procedure was carried out in the same manner as in Example 2, except that oxolinic acid was used at 0.008% by mass, and the preheat treatment process was performed at an ambient temperature of 210°C for 1 minute with a set width of 150 cm.

[0047] [Example 4] In Example 3, the procedure was carried out in the same manner as in Example 3, except that the preheat treatment process was performed at an ambient temperature of 190°C for 1 minute with a set width of 148 cm.

[0048] [Example 5] In Example 3, the procedure was carried out in the same manner as in Example 3, except that the preheat treatment process was performed at an ambient temperature of 170°C for 1 minute with a set width of 147 cm.

[0049] [Example 6] In Example 3, the procedure was carried out in the same manner as in Example 3, except that the preheat treatment process was performed at an ambient temperature of 150°C for 1 minute with a set width of 146 cm.

[0050] [Example 7] In Example 3, the procedure was carried out in the same manner as in Example 3, except that the preheat treatment process was performed at an ambient temperature of 130°C for 1 minute with a set width of 145 cm.

[0051] [Comparative Example 1] In Example 1, the procedure was carried out in the same manner as in Example 1, except that no post-heat treatment was performed.

[0052] [Comparative Example 2] In Example 2, the procedure was carried out in the same manner as in Example 2, except that preheat treatment was not performed.

[0053] [Comparative Example 3] In Example 3, the procedure was carried out in the same manner as in Example 3, except that preheat treatment was not performed.

[0054] [Comparative Example 4] In Example 3, the procedure was carried out in the same manner as in Example 3, except that the preheat treatment process was performed at an ambient temperature of 100°C for 1 minute with a set width of 144 cm.

[0055] [Comparative Example 5] In Example 3, the procedure was carried out in the same manner as in Example 3, except that the preheat treatment process was performed at an ambient temperature of 230°C for 1 minute with a set width of 144 cm.

[0056] [Comparative Example 6] In Example 4, the procedure was carried out in the same manner as in Example 4, except that the preheat treatment process was performed at an ambient temperature of 190°C for 1 minute with a set width of 143 cm.

[0057] [Comparative Example 7] In Example 4, the procedure was carried out in the same manner as in Example 4, except that the preheat treatment process was performed at an ambient temperature of 190°C for 1 minute with a set width of 154 cm.

[0058] [Example 8] (1) Pre-heat treatment process A 148cm wide fabric, using 167T-48F polyester fibers (single fiber fineness: 3.5 dtex) for both warp and weft threads, was heat-treated with dry heat at an ambient temperature of 210°C for 1 minute at a set width of 150cm to produce a fibrous base material containing polyester fibers (pickup rate: 70%).

[0059] (2) Process liquid preparation step A pad processing solution consisting of a quinoline compound was prepared. The ratio of the mass of the quinoline compound to the mass of the processing solution was adjusted as follows. • Quinoline compound: Oxolinic acid, 0.008% by mass.

[0060] (3) Chemical treatment process A fibrous substrate containing polyester fibers was immersed in the pad processing solution prepared above, and then compressed with a mangle roller to ensure the solution adhered to it. After that, the fibrous substrate containing polyester fibers was placed in a pin tenter and subjected to moist heat treatment at an ambient temperature of 130°C for 2 minutes.

[0061] (4) Post-heat treatment process A fibrous substrate containing chemically treated polyester fibers was set in a pin tenter, and a dry heat setting was performed at an ambient temperature of 170°C for 1 minute to obtain a polyester fiber structure.

[0062] [Example 9] In Example 8, the procedure was carried out in the same manner as in Example 8, except that the preheat treatment process was performed at an ambient temperature of 190°C for 1 minute with a set width of 148 cm.

[0063] [Example 10] In Example 8, the procedure was carried out in the same manner as in Example 8, except that the preheat treatment process was performed at an ambient temperature of 170°C for 1 minute with a set width of 147 cm.

[0064] [Example 11] In Example 8, the procedure was carried out in the same manner as in Example 8, except that the preheat treatment process was performed at an ambient temperature of 150°C for 1 minute with a set width of 146 cm.

[0065] [Comparative Example 8] In Example 8, the procedure was carried out in the same manner as in Example 8, except that preheat treatment was not performed.

[0066] [Comparative Example 9] In Example 8, the procedure was carried out in the same manner as in Example 8, except that the preheat treatment process was performed at an ambient temperature of 100°C for 1 minute with a set width of 144 cm.

[0067] [Comparative Example 10] In Example 8, the procedure was carried out in the same manner as in Example 8, except that the preheat treatment process was performed at an ambient temperature of 230°C for 1 minute with a set width of 144 cm.

[0068] [Table 1]

[0069] As shown in Table 1, in Examples 1 to 11, where preheat treatment was performed before the chemical treatment process, the antibacterial activity values ​​before washing (A0-F) and the antibacterial activity values ​​after 50 high-temperature accelerated washes (A 50 In all cases of -F), the value was greater than 0.0, indicating good antibacterial properties and wash durability. On the other hand, in Comparative Example 1, which did not undergo post-heat treatment, Comparative Examples 2, 3, and 8, which did not undergo pre-heat treatment, Comparative Examples 4 and 9, which underwent pre-heat treatment at 100°C, Comparative Examples 5 and 10, which underwent pre-heat treatment at 230°C, and Comparative Examples 6 and 7, where the change rate of weave density in the warp direction was less than -3.0% or greater than 3.0%, the antibacterial properties before washing were good, but the wash durability was poor.

[0070] [Example 12] (1) Pre-heat treatment process A 142cm wide fabric, using polyester fibers with a single fiber fineness of 0.3 dtex for both the warp and weft, was heat-treated at an ambient temperature of 190°C for 1 minute, under tension sufficient to eliminate wrinkles at a set width of 142cm, to produce a fibrous base material containing polyester fibers.

[0071] (2) Process liquid preparation step A treatment solution consisting of a quinoline compound and a staining acid was prepared. The following chemicals were used, and the mass ratio of each chemical to the mass of the treatment solution was adjusted as follows. • Quinoline compound: Oxolinic acid, 0.015% by mass • Staining acid: Mixed aqueous solution of 70% by mass acetic acid / 30% by mass sodium acetate, 0.005% by mass In addition, in the "Manufacturing Method" column of Table 2, "the ratio of the mass of the quinoline compound to the mass of the processing solution" is written as "quinoline compound".

[0072] (3) Chemical treatment process A fibrous substrate containing polyester fibers was immersed in the treatment solution prepared above and subjected to chemical treatment under pressure at 130°C for 30 minutes in a bath processing machine. Afterward, the fibrous substrate containing polyester fibers was removed from the bath processing machine and washed and dewatered. The bath processing machine used was the following apparatus, and the bath ratio was as follows. • Bath processing machine: 12-color rotary pot dyeing test machine (MINI-COLOUR 12EL model: manufactured by Texam Giken Co., Ltd.) Bath ratio (mass of fibrous substrate containing polyester fibers:mass of treatment solution): 1:10.

[0073] (4) Post-heat treatment process A fibrous substrate containing chemically treated polyester fibers was set in a pin tenter, and a dry heat setting was performed at an ambient temperature of 170°C for 1 minute to obtain a polyester fiber structure.

[0074] [Example 13] The procedure was carried out in the same manner as in Example 12, except that a 142 cm wide fabric was used, with polyester fibers with a single fiber fineness of 0.7 dtex for both the warp and weft.

[0075] [Example 14] The procedure was carried out in the same manner as in Example 12, except that a 142 cm wide fabric was used, with polyester fibers having a single fiber fineness of 1.4 dtex for both the warp and weft.

[0076] [Example 15] The procedure was carried out in the same manner as in Example 12, except that a 142 cm wide fabric was used, with polyester fibers having a single fiber fineness of 1.8 dtex for both the warp and weft.

[0077] [Example 16] The procedure was carried out in the same manner as in Example 12, except that a 142 cm wide fabric was used, with polyester fibers having a single fiber fineness of 3.7 dtex for both the warp and weft.

[0078] [Comparative Example 11] The procedure was carried out in the same manner as in Example 12, except that a 142 cm wide fabric was used, with polyester fibers with a single fiber fineness of 0.1 dtex for both the warp and weft.

[0079] [Comparative Example 12] The procedure was carried out in the same manner as in Example 12, except that a 142 cm wide fabric was used, with polyester fibers with a single fiber fineness of 5.5 dtex for both the warp and weft.

[0080] [Example 17] The procedure was carried out in the same manner as in Example 14, except that the amount of oxolinic acid was changed to 0.012% by mass.

[0081] [Example 18] The procedure was carried out in the same manner as in Example 14, except that the amount of oxolinic acid was changed to 0.009% by mass.

[0082] [Example 19] The procedure was carried out in the same manner as in Example 14, except that the amount of oxolinic acid was changed to 0.006% by mass.

[0083] [Comparative Example 13] The procedure was carried out in the same manner as in Example 14, except that the amount of oxolinic acid was changed to 0.003% by mass.

[0084] [Example 20] The procedure was carried out in the same manner as in Example 14, except that the fabric was changed to a 142 cm wide woven fabric using a polyester / cotton blend fiber (polyester fiber: 86% by mass, cotton fiber: 14% by mass, single fiber fineness of the blend fiber: 2.1 dtex).

[0085] [Example 21] The procedure was carried out in the same manner as in Example 14, except that the fabric was changed to a 142 cm wide woven fabric using a polyester / cotton blend fiber (polyester fiber: 78% by mass, cotton fiber: 22% by mass, single fiber fineness of the blend fiber: 2.3 dtex).

[0086] [Example 22] The procedure was carried out in the same manner as in Example 14, except that the fabric was changed to a 142 cm wide woven fabric using a polyester / cotton blend fiber (polyester fiber: 65% by mass, cotton fiber: 35% by mass, single fiber fineness of the blend fiber: 1.1 dtex).

[0087] [Example 23] The procedure was carried out in the same manner as in Example 14, except that the fabric was changed to a 142 cm wide woven fabric using a polyester / cotton blend fiber (polyester fiber: 55% by mass, cotton fiber: 45% by mass, single fiber fineness of the blend fiber: 1.1 dtex).

[0088] [Example 24] The procedure was carried out in the same manner as in Example 14, except that the fabric was changed to a 142 cm wide woven fabric using a polyester / cotton blend fiber (polyester fiber: 40% by mass, cotton fiber: 60% by mass, single fiber fineness of the blend fiber: 1.1 dtex).

[0089] [Table 2]

[0090] As shown in Table 2, when the single fiber fineness is 0.3 to 5.0 dtex, the antibacterial activity value before washing (A0-F) and the antibacterial activity value after 50 high-temperature accelerated washes (A0-F) are shown. 50In all cases (-F), the value was greater than 0.0, indicating good antibacterial properties. On the other hand, when fiber substrates with a single fiber fineness of up to 0.1 dtex or up to 5.5 dtex were used, the antibacterial properties were poor. Furthermore, when the ratio of the mass of the quinoline compound to the mass of the treatment solution was 0.004% by mass or more, the antibacterial properties were good, but when it was less than 0.004% by mass, the antibacterial properties were poor. In addition, it was confirmed that the antibacterial properties decreased with decreasing proportion of polyester fibers in the polyester fiber structure, and that the antibacterial properties remained good up to a polyester fiber ratio of 40% by mass.

[0091] [Example 25] (1) Pre-heat treatment process A 142cm wide fabric, using polyester fibers with a single fiber fineness of 1.4 dtex for both the warp and weft, was heat-treated at an ambient temperature of 190°C for 1 minute, under tension sufficient to eliminate wrinkles at a set width of 142cm, to produce a fibrous base material containing polyester fibers.

[0092] (2) Process liquid preparation step A treatment solution consisting of a quinoline compound, a disperse dye, a dyeing acid, and a leveling agent was prepared. The following agents were used, and the mass ratio of each agent to the mass of the treatment solution was adjusted as follows. • Quinoline compound: Oxolinic acid, 0.008% by mass • Disperse dye (Dianix Black CC-Rnew (Dystar Co., Ltd.), 0.5% by mass) • Staining acid: Mixed aqueous solution of 70% by mass acetic acid / 30% by mass sodium acetate, 0.050% by mass • Dyeing agent: "Ionet" (registered trademark) RAP-250 (Sanyo Chemical Industries, Ltd.), 0.050% by mass In addition, in the "Manufacturing Method" column of Table 3, "the ratio of the mass of the quinoline compound to the mass of the processing solution" is written as "quinoline compound".

[0093] (3) Chemical treatment process A fibrous substrate containing polyester fibers was immersed in the treatment solution prepared above and subjected to chemical treatment in a bath processing machine under pressure at an ambient temperature of 130°C for 30 minutes. After that, the fibrous substrate containing polyester fibers was removed from the bath processing machine and washed with water. The bath processing machine used was the following apparatus, and the bath ratio was as follows. • Bath processing machine: 12-color rotary pot dyeing test machine (MINI-COLOUR 12EL model: manufactured by Texam Giken Co., Ltd.) • Bath ratio (mass of fiber substrate containing polyester fibers:mass of treatment solution): 1:10 Subsequently, the fibrous substrate containing polyester fibers was immersed in a treatment solution prepared with a reducing cleaning agent, and a reducing cleaning treatment was performed in a bath processing machine at atmospheric pressure and 80°C for 20 minutes. The following equipment was used for the bath processing machine, and the bath ratio was as follows. • Bath processing machine: 12-color rotary pot dyeing test machine (MINI-COLOUR 12EL model: manufactured by Texam Giken Co., Ltd.) • Reducing cleaning agents: Sodium hydroxide (Nacalai Tesque Co., Ltd.), 0.007% by mass; Sodium hydrosulfite (Nacalai Tesque Co., Ltd.), 0.020% by mass; "Gran-Up" (registered trademark) US-20 (Meisei Chemical Industry Co., Ltd.), 0.005% by mass Bath ratio (mass of fibrous substrate containing polyester fibers:mass of treatment solution): 1:20.

[0094] (4) Post-heat treatment process A fibrous substrate containing chemically treated polyester fibers was set in a pin tenter, and a dry heat setting was performed at an ambient temperature of 170°C for 1 minute to obtain a polyester fiber structure.

[0095] [Example 26] The procedure was carried out in the same manner as in Example 25, except that the amount of oxolinic acid was changed to 0.015% by mass.

[0096] [Example 27] In Example 25, the procedure was carried out in the same manner as in Example 25, except that the amount of oxolinic acid was changed to 0.030% by mass.

[0097] [Example 28] The procedure was carried out in the same manner as in Example 25, except that the amount of oxolinic acid was changed to 0.045% by mass.

[0098] [Table 3]

[0099] As shown in Table 3, when oxolinic acid was used at 0.030% by mass, the antibacterial properties were good both before washing and after 50 high-temperature accelerated washes. However, the brightness L was lower than in Examples 25 and 26. * The value increased. Furthermore, when the oxolinic acid content was reduced to 0.045% by mass, the lightness L * It rose sharply. [Industrial applicability]

[0100] The polyester fiber structure provided by the method for manufacturing the polyester fiber structure of the present invention exhibits excellent antibacterial properties and wash durability. Such a polyester fiber structure can be applied to various uses where high antibacterial properties are required, and can be used as fabric for clothing, bedding, towels, rugs, curtains, sheets, etc., and is also suitable for use in medical uniforms.

Claims

1. A pre-heat treatment step in which a fiber substrate containing polyester fibers with a single fiber fineness of 0.3 dtex or more and 5.0 dtex or less is heat-treated at an ambient temperature of 110°C or more and 210°C or less so that the rate of change in the weave density in the warp direction of the fiber substrate containing the polyester fibers is -3.0% or more and 3.0% or less before and after heat treatment, A process for preparing a treatment solution, which involves preparing a treatment solution containing at least one compound selected from oxolinic acid, ciprofloxacin, levofloxacin, moxifloxacin, garenoxacin, and sitafloxacin in an amount of 0.004% by mass or more relative to the mass of the treatment solution, A chemical treatment step in which a fibrous substrate containing the polyester fibers is immersed in the aforementioned treatment solution and treated by bath processing or pad processing, A post-heat treatment step in which the fibrous substrate containing the chemically treated polyester fibers is subjected to dry heat treatment, A method for producing a polyester fiber structure having the following characteristics.

2. A method for producing a polyester fiber structure according to claim 1, wherein the fibers constituting the fiber base material containing the polyester fibers include 40% by mass or more of polyester fibers having a single fiber fineness of 0.3 dtex or more and 5.0 dtex or less, relative to the total mass of the fiber base material.

3. The method for producing a polyester fiber structure according to claim 1 or 2, wherein at least one compound selected from oxolinic acid, ciprofloxacin, levofloxacin, moxifloxacin, garenoxacin, and sitafloxacin is oxolinic acid.

4. A method for producing a polyester fiber structure according to claim 1 or 2, wherein in the chemical treatment step performed by the bath processing described above, the bath ratio of the treatment solution (mass of the fiber base material containing the polyester fibers: mass of the treatment solution) is 1:5 to 1:

30.

5. A method for manufacturing a medical uniform, comprising the step of sewing a medical uniform using a polyester fiber structure manufactured by the method for manufacturing a polyester fiber structure described in claim 1 or 2.

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